Charlenger 1870

3
Table of Contents
Table of Contents
Disassembly and Assembly Section
Alternator - Remove and Install ........................... 4
Electric Starting Motor - Remove and Install ....... 5
Fuel Filter and Fuel Filter Base - Remove (Primary
and Secondary Fuel Filters) ................................ 6
Fuel Filter and Fuel Filter Base - Install (Primary and
Secondary Fuel Filters) ....................................... 8
Cooling Assembly - Remove ................................. 10
Cooling Assembly - Install .................................... 12
Hydraulic Oil Cooler - Remove and Install ........... 15
Air Cleaner - Remove and Install .......................... 18
Aftercooler - Remove and Install .......................... 20
Muffler - Remove and Install ................................ 21
Water Temperature Regulator - Remove and Install
............................................................................. 22
Radiator - Remove ............................................... 24
Radiator - Install ................................................... 26
Fan - Remove and Install ..................................... 29
Fan Drive - Remove ............................................. 30
Fan Drive - Disassemble ...................................... 31
Fan Drive - Assemble .......................................... 32
Fan Drive - Install .................................................. 33
Water Pump - Remove and Install ....................... 33
Crankshaft Front Seal - Remove and Install ......... 35
Air Compressor - Remove and Install .................. 37
Refrigerant Compressor - Remove and Install ..... 38
Refrigerant Accumulator (With Desiccant) - Remove
and Install ............................................................ 39
Refrigerant Condenser - Remove and Install ....... 41
Hood - Remove .................................................... 42
Hood - Install ........................................................ 44
Drive Shaft - Remove and Install ......................... 46
Engine - Remove ................................................. 47
Engine - Install ..................................................... 51
Index Section
Index ..................................................................... 56
Accidental machine starting can cause injury or

death to personnel working on the machine.
To avoid accidental machine starting, turn the bat-

tery disconnect switch to the OFF position and re-
move the key. If the machine is not equipped with
a battery disconnect switch, disconnect the bat-
tery cables from the battery and tape the battery
clamps.
Place a do not operate tag at the battery discon-

nect switch location to inform personnel that the
machine is being worked on.
4
Disassembly and Assembly

Section
i01616001
Alternator - Remove and Install

SMCS Code: 1405-010
Removal Procedure
1. Remove the guard assembly on the right side of
the radiator. Refer to Operation and Maintenance
Manual, “Guards - Remove and Install”.
2. Turn the disconnect switch to the Off position.
3. Remove the belt. Refer to Operation and

Maintenance Manual, “Belt (Alternator and Water
Pump) - Replace”. Illustration 2 g00839856
5. Remove bolts (5), (6), (7), and (8).
6. Remove alternator (2) from the bracket.
Installation Procedure
g00839840
Illustration 1
4. Remove wiring (1), (3), and (4) from alternator

(2).
g00839856
Illustration 3
1. Place alternator (2) in position on the bracket.
2. Install bolts (7), (8), (6), and (5) in order to hold

the alternator in position.
5
g00842304
Illustration 5
3. Disconnect wires (1), (2), (5), and (6).
4. Remove bolts (3) and electric starting motor (4)

from the machine.
g00839840
Illustration 4
3. Install wiring (4), (3), and (1) to alternator (2).
Note: Remove the paint from the bores and the
4. Install the belt. Refer to Operation and threads of bolts (3) before the installation procedure.
Pump) - Replace”.
5. Install the guard assembly on the right side of

the radiator. Refer to Operation and Maintenance
6. Turn the disconnect switch to the On position.
i01626476
Electric Starting Motor -

Remove and Install
g00842304
SMCS Code: 1453-010 Illustration 6
1. Install electric starting motor (4) in the tractor

Removal Procedure with bolts (3).
1. Raise the hood. Refer to Operation and 2. Connect wires (6), (5), (2), and (1) to the electric
Maintenance Manual, “Hood (Engine starting motor.
Compartment) - Raise/Lower”.
3. Turn the battery disconnect switch to the ON
2. Turn the battery disconnect switch to the OFF position.
position.
4. Lower the hood. Refer to Operation and
Maintenance Manual, “Hood (Engine
6
i01685068
Fuel Filter and Fuel Filter Base

Fuel leaked or spilled onto hot surfaces or elec-
- Remove trical components can cause a fire. To help pre-
(Primary and Secondary Fuel vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Filters) Clean up fuel spills immediately.
SMCS Code: 1261-011; 1262-011
Removal Procedure
Table 1
Required Tools
Part
Tool Description Qty
Number
9U-7070 Cap 4
A
9U-7072 Cap 4
Note: Mark the location and the orientation of all

hose assemblies for reassembly purposes before
the removal of any components. Plug all hose
assemblies and cap all fittings. Plugs and caps
help prevent fluid spills. Plugs and caps also help
prevent dirt and debris from entering the fuel
system.
g00869265
Illustration 7
NOTICE (1) Secondary fuel filter and filter base
Care must be taken to ensure that fluids are contained (2) Primary fuel filter and filter base
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Park the machine on a level surface and raise
collect the fluid with suitable containers before open- the hood.
ing any compartment or disassembling any compo-
nent containing fluids. 2. Turn fuel valve (5) to the OFF position.
Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and

mandates.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
7
Primary Fuel Filter and Filter Base Secondary Fuel Filter and Filter Base
g00869008
Illustration 9
1. Disconnect hose assemblies (3) and (4) from

filter base (15). Cap the hose assemblies with
Tooling (A).
g00869131 2. Remove two port connectors (18) from filter base

Illustration 8
(15). Remove O-ring seals (17) from the port
connectors.
1. Disconnect two hose assemblies (6) and (7) from
filter base (8). Cap the hose assemblies and 3. If necessary, remove four plugs (21) from filter
plug the filter base with Tooling (A). base (15). Remove O-ring seals (20) from the
plugs.
2. Disconnect hose (14) from water separator bowl
(13). 4. Remove filter element (19) from filter base (15).
3. Remove water separator bowl (13) from fuel filter 5. Remove four bolts (16) which fasten filter base
element (12). (15) to the machine.
4. Remove fuel filter element (12) from filter base 6. Remove stud (15A) from filter base (15).
(8).
5. Remove four bolts (9) which fasten filter base (8)

to the machine. Remove the filter base.
6. If necessary, remove five plugs (10) and remove

O-ring seals (11) from the plugs.
7. Remove stud (8A) from filter base (8).

8
i01686105 Primary Fuel Filter and Filter Base

Fuel Filter and Fuel Filter Base
- Install
(Primary and Secondary Fuel
Filters)
SMCS Code: 1261-012; 1262-012
NOTICE
Care must be taken to ensure that fluids are contained
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
nent containing fluids.

products.

mandates.
g00869131
Illustration 10
1. Inspect all of the O-ring seals for wear or for

Hot engine components can cause injury from damage. If necessary, install new parts.
engine, allow the engine and the components to 2. Install O-ring seals (11) on plugs (10). Install
cool. plugs (10) in filter base (8).
3. Install stud (8A) in fuel filter base (8). Tighten the

stud to 70 ± 15 N·m (52 ± 11 lb ft).
Fuel leaked or spilled onto hot surfaces or elec- 4. Install four washers and bolts (9) which fasten
trical components can cause a fire. To help pre- filter base (8) to the machine.
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements. 5. Install water separator bowl (13) on fuel filter
Clean up fuel spills immediately. element (12). Install fuel filter element (12) and
water separator bowl (13) on filter base (8).
6. Connect hose (14) to water separator bowl (13).

9
4. Install filter base (15) and secure the filter base

with four washers and bolts (16).
5. Install O-ring seals (17) on port connectors (18).

Install the port connectors in filter base (15).
6. Install filter element (19) on filter base (15).
g00869265
Illustration 11
(1) Secondary fuel filter and filter base
(2) Primary fuel filter and filter base
7. Connect hose assemblies (6) and (7) to filter

base (8).
g00869265
Secondary Fuel Filter and Filter Base Illustration 13
(1) Secondary fuel filter and filter base
(2) Primary fuel filter and filter base
7. Connect hose assemblies (3) and (4) to filter

base (15).
8. Turn the fuel valve (5) to the ON position.
9. Close the hood.
10. Prime the fuel system and start the engine.

Both of the filters must be primed. Refer to the
Operation and Maintenance Manual, SEBU7431,
“Fuel Filter (Secondary) - Replace”. Refer to the
Operation and Maintenance Manual, SEBU7431,
“Fuel Filter (Primary) - Clean/Replace”.
11. Inspect both fuel filters and filter bases for leaks.
g00869008
Illustration 12
1. Inspect all of the O-ring seals for wear or for

damage.
2. Install O-ring seals (20) on plugs (21). Install

plugs (20) in filter base (15).
3. Install stud (15A) in filter base (15). Tighten the

stud to a torque of 70 ± 15 N·m (52 ± 11 lb ft).
10
i01654132
Cooling Assembly - Remove

Personal injury can result from contact with refrig-
SMCS Code: 1063-011; 1351-011; 1374-011; erant.
1810-011
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Removal Procedure
Protective goggles must always be worn when re-
Table 2
frigerant lines are opened, even if the gauges in-
Required Tools dicate the system is empty of refrigerant.
Part Part
Tool Qty Always use precaution when a fitting is removed.
Number Description
Slowly loosen the fitting. If the system is still under
Face Seal pressure, release it slowly in a well ventilated area.
6V-9512 2
Plug
Cap Personal injury or death can result from inhaling
6V-9833 2 refrigerant through a lit cigarette.
A Assembly
6V-9513 Plug 2 Inhaling air conditioner refrigerant gas through a
Cap lit cigarette or other smoking method or inhaling
6V-9834 2 fumes released from a flame contacting air con-
Assembly
ditioner refrigerant gas, can cause bodily harm or
B 138-7573 Link Bracket 2 death.
Start By: Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
a. Remove the hood. Refer to Disassembly and
Assembly, “Hood - Remove”. Use a certified recovery and recycling cart to prop-
erly remove the refrigerant from the air condition-
b. Remove the batteries. Refer to Disassembly and ing system.
Assembly, “Batteries - Remove and Install”.
1. Remove the engine guards. Refer to Operation
c. Remove the air cleaner. Refer to Disassembly and Maintenance Manual, “Guards - Remove
and Assembly, “Air Cleaner - Remove”. and Install”.
Note: Put identification marks on all hoses, on all 2. Drain the coolant from the cooling system into a
hose assemblies, on all wires, and on all tube suitable container for storage or disposal. The
assemblies for installation purposes. Plug all capacity of the cooling system is approximately
hose assemblies and all tube assemblies. This 37 L (10 US gal). Refer to Operation and
helps to prevent fluid loss, and this helps to keep Maintenance Manual, “Cooling System Coolant
contaminants from entering the system. (DEAC) - Change” or Operation and Maintenance
Manual, “Cooling System Extended Life Coolant -
NOTICE Change” for the machine that is being serviced.
during performance of inspection, maintenance, test- 3. Recover the air conditioner refrigerant from the air
ing, adjusting and repair of the product. Be prepared to conditioner system. The correct charge is 2.2 kg
collect the fluid with suitable containers before open- (4.9 lb). Refer to Service Manual, SENR5664, “Air
ing any compartment or disassembling any compo- Conditioning and Heating Systems with R-134a
nent containing fluids. Refrigerant” for the procedure. Refer to Special
Publication, NEDG5065, “Air Conditioning Tools”
Refer to Special Publication, NENG2500, “Caterpillar for the tools.
products.

mandates.
11
9. Remove bolts (3) from the bracket assembly.

Remove bolts (9) from the radiator. Remove
support assembly (4). Remove the support
assembly on the other side of the engine.
g00854182
Illustration 14
4. Remove hose assemblies (1).
5. Plug hose assemblies with Tooling (A) and cap Illustration 16

g00854275
all fittings with Tooling (A).
10. Loosen the clamps on hoses (10), (12), (15),
6. Disconnect hose assemblies (2) and cap hose and (14).
assemblies.
11. Disconnect hoses (10), (12), (15), and (14).
12. Disconnect tubes (11) and (13).
g00854276
Illustration 17
13. Loosen the clamps on hoses (16) and (17).

g00854212 Remove hoses (16) and (17).
Illustration 15
7. Remove bolt (8) and the bracket.
8. Remove bolt (7) on the other side of the bracket.

Remove clamp (6) and refrigerant accumulator
(5) from the bracket.
12
g00854278 g00854290
Illustration 18 Illustration 20
14. Loosen the clamp on hose (18) and hose (19) 16. Remove four bolts (21).
that is connected to the radiator. Remove hoses
(18) and (19) from the radiator. 17. Remove cooling package (20). The weight of
the cooling package is approximately 127 kg
(280 lb).
i01711902
Cooling Assembly - Install

SMCS Code: 1063-012; 1351-012; 1374-012;
1810-012
Table 3
Required Tools
Part Part
Tool Qty
Number Description
Face Seal
6V-9512 2
Plug
Cap
6V-9833 2
A Assembly
6V-9513 Plug 2
Cap
6V-9834 2
Assembly
B 138-7573 Link Bracket 2
g00854279
Illustration 19
Note: Check the O-ring seals for wear or for
15. Attach Tooling (B) to cooling package (20). Use damage. Replace the O-ring seals, if necessary.
chains and a suitable lifting device to support
the cooling package.
13
NOTICE

products.

mandates.

erant.


g00854279
dicate the system is empty of refrigerant. Illustration 21
Always use precaution when a fitting is removed. 1. Attach Tooling (B) to cooling package (20). Use
Slowly loosen the fitting. If the system is still under chains, a suitable lifting device, and Tooling (B)
pressure, release it slowly in a well ventilated area. to place the cooling package in the original
position. The weight of the cooling package is
Personal injury or death can result from inhaling approximately 127 kg (280 lb).
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
death.
Do not smoke when servicing air conditioners or

Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.
g00854290
Illustration 22
2. Install four bolts (21).

14
g00854182 g00854212
3. Connect hose assemblies (1). 8. Install support assembly (4). Install bolts (3) on
the bracket assembly. Install bolts (9) on the
4. Connect hose assemblies (2). radiator.
9. Install bolt (7) on the other side of the bracket.

Install clamp (6) and refrigerant accumulator (5)
on the bracket.
10. Install bolt (8) and the bracket.
11. Install the support assembly on the other side

of the engine.
g00854275
Illustration 24
5. Connect hoses (10), (12), (15), and (14). Illustration 26

g00854276
6. Connect tubes (11) and (13). 12. Install hoses (16) and (17). Tighten the clamps
on hoses (16) and (17).
7. Tighten the clamps on hoses (10), (12), (15), and
(14) to 6.7 N·m (59.30 lb in).
15
15. Charge the refrigerant system. The correct

charge is 2.2 kg (4.9 lb). Refer to Service Manual,
RENR1860, “Refrigerant System - Charge” for
the procedure. Refer to Special Publication,
NEDG5065, “Air Conditioning Tools” for the tools.
16. Refill the cooling system. The capacity of the

cooling system is approximately 37 L (10 US gal).
Refer to Operation and Maintenance Manual,
“Cooling System Coolant (DEAC) - Change” or
Operation and Maintenance Manual, “Cooling
System Extended Life Coolant - Change” for the
machine that is being serviced.
17. Install the engine guards. Refer to Operation

and Maintenance Manual, “Guards - Remove
and Install”.
End By:
a. Install the air cleaner. Refer to Disassembly and

Illustration 27 g00854278 Assembly, “Air Cleaner - Remove”.
13. Install hoses (18) and (19) to the radiator. b. Install the batteries. Refer to Disassembly and
Tighten the clamp on hose (18) and hose (19) Assembly, “Batteries - Remove and Install”.
that is connected to the radiator.
c. Install the hood. Refer to Disassembly and
Assembly, “Hood - Remove”.
i01632630
Hydraulic Oil Cooler - Remove

and Install
SMCS Code: 1374-010
Removal Procedure
Start By:

Assembly, “Hood - Remove and Install”.
b. Remove the aftercooler. Refer to Disassembly

and Assembly, “Aftercooler - Remove and
Install”.
c. Remove the refrigerant condenser. Refer to

Disassembly and Assembly, “Refrigerant
Condenser - Remove and Install”.
Note: Put identification marks on all hose assemblies

g00854279
for installation purposes. Plug all hose assemblies.
Illustration 28 This helps to prevent fluid loss, and this helps to
keep contaminants from entering the system.
14. Remove Tooling (B) from the cooling package
(20).
16
NOTICE

products.

mandates.
g00845673
Illustration 30
g00845664
Illustration 29
1. Disconnect hose assemblies (1), (2), (3), and (4)

under the hydraulic oil cooler.
g00845680
Illustration 31
2. Remove bolts (9), the spacers, and bolts (7) on

each side of hydraulic oil cooler (8).
3. Attach a suitable lifting device to the hydraulic

oil cooler. The weight of the hydraulic oil cooler
is approximately 38 kg (83 lb).
17
4. Remove bolts (6) on each side of the hydraulic

oil cooler. Remove plate (5) and hydraulic oil
cooler (8) from the bracket.
damage. Replace the O-ring seals, if necessary.
1. Attach a suitable lifting device to the hydraulic

oil cooler. The weight of the hydraulic oil cooler
g00845673
Illustration 33
2. Place hydraulic oil cooler (8) in position in the

bracket. Install plate (5) with bolts (6) on each
side of the hydraulic oil cooler.
g00845680 3. Install bolts (7), bolts (9), and the spacers to
Illustration 32
each side of the hydraulic oil cooler.
g00845664
Illustration 34
4. Connect hose assemblies (4), (3), (2), and (1).
End By:
a. Install the refrigerant condenser. Refer to

Condenser - Remove and Install”.
b. Install the aftercooler. Refer to Disassembly and

Assembly, “Aftercooler - Remove and Install”.
18

Assembly, “Hood - Remove and Install”.
i01633596
Air Cleaner - Remove and

Install
SMCS Code: 1051-010; 1054-010
Removal Procedure
Hot engine components can cause injury from

engine, allow the engine and the components to
cool.
g00846098
1. Open the hood. Refer to Operation and Illustration 36
Compartment) - Raise/Lower”. 4. Remove bolts (5) on each side of plate (6).
Remove plate (6).
5. Remove bolts (4) on each side and remove

brace assembly (3).
6. Remove bolts (8) and support assembly (7).
g00846108
g00846087 Illustration 37
Illustration 35
Note: The turbocharger was removed for illustrative
2. Loosen clamp (1) and remove clamp (1) from the purposes.
turbocharger inlet and the air cleaner.
7. Remove bolt (9), the bracket, and hose assembly
3. Loosen clamp (2) and slide the clamp down the (10) from the support.
hose.
The hose will be removed from the dust ejector

when the air cleaner is removed from the
machine.
19
g00846119 g00846119
8. Remove bolts (13), support (11), and air cleaner

(12) from the machine.
g00846882
Illustration 39
9. Remove bolts (15), washers (14), and support

(11) from air cleaner (12). Illustration 42 g00846087
Installation Procedure 2. Place air cleaner (12) and support (11) in

position on the machine. Place the hose to the
ejector in position. Install bolts (13).
3. Place clamp (2) in position and tighten the

clamp.
4. Install clamp (1) to the turbocharger inlet and the

air cleaner. Tighten the clamp.
g00846882
Illustration 40
1. Install support (11) to air cleaner (12) with

washers (14) and bolts (15).
20
i01632126
Aftercooler - Remove and

Install
SMCS Code: 1063-010
Removal Procedure
1. Raise the hood. Refer to Operation and
g00846108
Illustration 43
5. Place hose assembly (10) and the bracket in

position and install bolt (9) to the support.
g00845394
Illustration 45
2. Loosen the clamp on hose (3). Remove the hose

from the elbow of aftercooler (4). Repeat this
Step for the hose and the clamp on the other
side of the aftercooler.
g00846098
Illustration 44
3. Release latch assembly (5) on both sides of the
6. Install support assembly (7) with bolts (8). aftercooler.
7. Place brace assembly (3) in position and install 4. Remove clips (1) and pins (2) from the brace
bolts (4). assemblies.
8. Place plate (6) in position and install bolts (5) on 5. Remove aftercooler (4). The weight of the
each side of the plate. aftercooler is approximately 11 kg (25 lb).
9. Close the hood. Refer to Operation and

21
Installation Procedure i01626563
Muffler - Remove and Install

SMCS Code: 1062-010
Removal Procedure
g00845416
Illustration 46
g00842404
Illustration 48
1. Loosen clamp (2).
2. Remove bolts (4) and muffler assembly (1) from

the lower support assembly and exhaust tube
assembly (3).
3. Remove the sealant from the muffler and the

support assembly.
g00845394
Illustration 47
1. Place aftercooler (4) in position and install pins

(2) and clips (1). The weight of the aftercooler is
approximately 11 kg (25 lb).
2. Fasten latch assemblies (5).
3. Slide hoses (3) on the elbows of aftercooler (4).

Tighten the clamps on the hoses.
4. Lower the hood. Refer to Operation and g00843329

Illustration 49
Compartment) - Raise/Lower”. 1. Apply a bead of 211-8713 Sealant on surface
(A) of the lower support assembly.
22
NOTICE

products.

mandates.
At operating temperature, the engine coolant is

Illustration 50 g00842404 hot and under pressure.
2. Position muffler assembly (1) on the lower Steam can cause personal injury.
support assembly and exhaust tube assembly
(3). Install bolts (4). Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
3. Tighten clamp (2) to a torque of 70 ± 10 N·m touch with your bare hand.
(52 ± 7 lb ft).
Remove the fill cap slowly to relieve pressure.
i01624505 Cooling system conditioner contains alkali. Avoid

contact with the skin and eyes to prevent personal
Water Temperature Regulator - injury.
Remove and Install
1. Drain the coolant from the cooling system into a
SMCS Code: 1355-010 suitable container for storage or disposal. The
capacity of the cooling system is approximately
Removal Procedure 37 L (10 US gal). Refer to Operation and
Maintenance Manual, “Cooling System Coolant
Table 4 (DEAC) - Change” or Operation and Maintenance
Required Tools Manual, “Cooling System Extended Life Coolant -
Change” for the machine that is being serviced.
Part
Tool Number Part Description Qty
A 1P-0510 Driver Gp 1
Start By:
a. Remove the alternator. Refer to Disassembly and

Assembly, “Alternator - Remove and Install”.
23
g00840834
Illustration 51
g00877563
Illustration 53
2. Loosen hose clamp (3) and clamp (6). Slide the
clamps away from the original position. 1. Use Tooling (A) in order to install seal (10) in
regulator housing assembly (5), as shown.
3. Disconnect tube assembly (1).
4. Remove radiator hose (2) from regulator housing

assembly (5).
5. Remove bolts (4).
6. Remove the regulator housing assembly from

hose (7).
g00877564
Illustration 54
g00840836
Illustration 52
7. Remove Gasket (8), water temperature regulator

(9), and seal (10) from regulator housing
assembly (5).
24
i01638195
Radiator - Remove
SMCS Code: 1353-011
Removal Procedure
Table 5
Required Tools
Part
A 138-7573 Link Bracket 2
Start By:

Assembly, “Hood - Remove”.
g00840834
Illustration 55 b. Remove the air cleaner. Refer to Disassembly
and Assembly, “Air Cleaner - Remove”.
2. Position water temperature regulator (9) in
regulator housing assembly (5). Position bolts c. Remove the fan. Refer to Disassembly and
(4) in the regulator housing assembly and install Assembly, “Fan - Remove”.
gasket (8).
Note: Put identification marks on all hoses and on
3. Slide the regulator housing assembly on hose all hose assemblies for installation purposes. Plug
(7) and place the regulator housing assembly all hose assemblies. This helps to prevent fluid loss,
in the original position. and this helps to keep contaminants from entering
the system.
Note: Before bolts (4) are tightened, the water
temperature regulator should be positioned correctly
NOTICE
in the regulator housing assembly.
4. Tighten bolts (4).
5. Slide radiator hose (2) on the regulator housing
assembly.
6. Attach clamp (6) and hose clamp (3).
7. Connect tube assembly (1).
products.
8. Fill the cooling system. The capacity of the
cooling system is approximately 37 L (10 US gal).
mandates.
“Cooling System Coolant (DEAC) - Change” or
System Extended Life Coolant - Change” for the 1. Drain the coolant from the cooling system into a
machine that is being serviced. suitable container for storage or disposal. The
End By: 37 L (9.8 US gal). Refer to Operation and
a. Install the alternator. Refer to Disassembly and (DEAC) - Change” or Operation and Maintenance
Assembly, “Alternator - Remove and Install”. Manual, “Cooling System Extended Life Coolant
- Change”.
25
2. Remove the guard assembly on the right side of 7. Loosen the clamps on hoses (8), (10), (13), and
the tractor. Refer to Operation and Maintenance (12).
8. Disconnect hose (8), hose (10), hose (13), hose
3. Remove the shroud on the right side of the (12), tube (9), and tube (11).
tractor.
g00848001
Illustration 58

Remove hoses (14) and (15).
g00839322
Illustration 56
4. Remove bolt (6) and the bracket.
5. Remove bolt (5) on the other side of the bracket.

Remove clamp (4) and refrigerant accumulator
6. Remove bolts (1) from the bracket assembly.

Remove bolts (7) from the radiator. Remove
support assembly (2). Remove the support
assembly on the other side of the engine.
g00847994
Illustration 59
10. Loosen the clamp on hose (16) and hose (17)

that is connected to the radiator. Remove hoses
(16) and (17) from the radiator.
g00847941
Illustration 57
26
g00848006 g00847979
11. Attach Tooling (A) to radiator (18). Use 12. Remove nuts (20) on both sides of the radiator.
chains and a suitable lifting device to support
the radiator. The weight of the radiator is 13. Release latches (19) on aftercooler (21). Open
approximately 45 kg (100 lb). the aftercooler.
14. Remove nut (22) on both sides of the radiator.
15. Remove the radiator from the tractor.
i01644421
Radiator - Install
SMCS Code: 1353-012
Table 6
Required Tools
Part
A 138-7573 Link Bracket 2
g00847985
Illustration 61
damage. Replace the O-ring seals, if necessary.
27
NOTICE

products.

mandates.
g00847985
Illustration 65
1. Attach Tooling (A) to radiator (18). Use a suitable

lifting device and Tooling (A) to place the radiator
in the original position. The weight of the radiator
2. Open the aftercooler. Install nut (22) on both

sides of the radiator.
3. Close the aftercooler. Secure latches (19) on

aftercooler (21).
4. Install nuts (20) on both sides of the radiator.
g00848006
Illustration 63
g00847994
Illustration 66
5. Connect hoses (16) and (17) to the radiator.

g00847979 Tighten the clamps on the hoses.
Illustration 64
28
g00848001
Illustration 67
6. Connect hoses (15) and (14) to the radiator.

Tighten the clamps on the hoses.
g00839322
Illustration 69
8. Install support assembly (2). Install bolts (1) to

the bracket assembly. Install bolts (7) to the
radiator. Install the support assembly on the
other side of the engine.
9. Place refrigerant accumulator (3) in the original

position on the bracket. Install clamp (4) with bolt
(5) on the other side of the bracket.
10. Install the bracket and bolt (6).
11. Install the shroud on the right side of the tractor.
12. Install the guard assembly on the right side of

the tractor. Refer to Operation and Maintenance
g00847941
Illustration 68 13. Fill the cooling system with coolant. The
7. Connect hose (12), hose (13), hose (10), hose 37 L (9.8 US gal). Refer to Operation and
(8), tube (11), and tube (9). Tighten the clamps Maintenance Manual, “Cooling System Coolant
on the hoses to a torque of 5 N·m (44 lb in). (DEAC) - Change” or Operation and Maintenance
Manual, “Cooling System Extended Life Coolant -
Change” for the machine that is being serviced.
End By:
a. Install the fan. Refer to Disassembly and

Assembly, “Fan - Install”.
b. Install the air cleaner. Refer to Disassembly and

Assembly, “Air Cleaner - Install”.

Assembly, “Hood - Install”.
29
i01614703
Fan - Remove and Install

SMCS Code: 1356-010
Removal Procedure
1. Remove the left hand guard assembly. Refer to
Operation and Maintenance Manual, “Guards
-Remove and Install”.
g00836040
Illustration 71
Typical Example
Note: A fan clutch is used on some models. The fan

clutch has no separate spacer.
5. Remove bolts (7), fan (5), and fan spacer (6).
g00835987 g00836040
Typical Example
2. Remove bolts (1) on the top of shroud (3).
1. Install fan spacer (6) and fan (5) with bolts (7).
3. Remove bolts (4) on the bottom of shroud (3).
Note: A fan clutch is used on some models. The fan
4. Remove two nuts (2) and remove left hand clutch has no separate spacer.
shroud (3).
30
g00849504
Illustration 74
2. Remove nuts (2) and shroud (1).
g00835987
Illustration 73
Typical Example
2. Install left hand shroud (3) with two nuts (2).
3. Install bolts (4) at the bottom of shroud (3).
4. Install bolts (1) at the top of shroud (3).
5. Install the left hand guard assembly. Refer to

- Remove and Install”.
i01637977
Fan Drive - Remove

SMCS Code: 1359-011 Illustration 75
g00837046
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.
1. Remove the guard assembly on the right hand

side. Refer to Operation and Maintenance
31
g00847593
Illustration 77
1. Remove bolts (1), washers (2), fan shaft (3), and

roller bearing assembly (4) from fan bearing
bracket (5).
g00837047 2. Remove grease fitting (6) from the fan bearing

Illustration 76
bracket, if necessary.
3. Remove belt (3). Refer to Operation and
Maintenance Manual, “Belt (Air Conditioner and
Fan) - Replace”.
4. Remove belt (6). Refer to Operation and

Pump) - Replace”.
5. Remove bolts (4) and fan pulley (5).
6. Remove bolts (7) and fan drive (8) from the

engine.
i01638074
g00847594
Illustration 78
Fan Drive - Disassemble
3. Remove bolts (10) and plate (9) from fan shaft
SMCS Code: 1359-015 (3).
4. Remove O-ring seal (8) from bearing retainer (7)

Disassembly Procedure and the roller bearing assembly.
Table 7
Required Tools
Part
A 8H-0663 Bearing Puller Gp 1
B 1P-0510 Driver Gp 1
Start By:
a. Remove the fan drive. Refer to Disassembly and

Assembly, “Fan Drive - Remove”.
g00847595
Illustration 79
32
5. Use a suitable press, Tooling (A), and Tooling

(B) to remove the fan shaft from roller bearing
assembly (4) and bearing retainer (7). Remove
the bearing retainer from the roller bearing
assembly.
i01638150
Fan Drive - Assemble

SMCS Code: 1359-016
Assembly Procedure
Table 8 g00847594
Illustration 81
Required Tools
2. Install O-ring seal (8) to bearing retainer (7) and
Part the roller bearing assembly.
1P-0510 Driver Gp 1 3. Position plate (9) on fan shaft (3) and install bolts
A
(10).
g00847593
Illustration 82
4. Position fan shaft (3) and roller bearing assembly

(4) in fan bearing bracket (5).
5. Install washers (2) and bolts (1).

g00847772
Illustration 80 6. Install grease fitting (6) in the fan bearing
bracket.
1. Use a suitable press and Tooling (A) to install
roller bearing assembly (4) and bearing retainer End By:
(7) to fan shaft (3).
a. Install the fan drive. Refer to Disassembly and
Assembly, “Fan Drive - Install”.
33
i01638134 4. Install belt (3). Refer to Operation and

Maintenance Manual, “Belt (Air Conditioner and
Fan Drive - Install Fan) - Replace”.
SMCS Code: 1359-012
g00849504
Illustration 85
5. Position shroud (1) on the radiator and install

nuts (2).
g00837047
Illustration 83
6. Install the guard assembly on the right hand side.
“Guards - Remove and Install”.
End By:
a. Install the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.
i01627648
Water Pump - Remove and

Install
SMCS Code: 1361-010
Removal Procedure
Start By:
g00837046
Illustration 84 a. Remove the alternator. Refer to Disassembly and
1. Position fan drive (8) on the engine and install
bolts (7).
2. Install fan pulley (5) with bolts (4).
3. Install belt (6). Refer to Operation and

Pump) - Replace”.
34
Note: Hose (1) can not be removed from the water

NOTICE pump until the water pump is removed.
during performance of inspection, maintenance, test- 5. Remove bolts (5) and mounting block (4).

products.

mandates.
1. Drain the coolant. Refer to Operation and

Maintenance Manual, “Cooling System Coolant Illustration 87
g00843267
(DEAC) - Change” or refer to Operation and
Maintenance Manual, “Cooling System Extended 6. Remove bolts (7) and water pump (8) from the
Life Coolant - Change” for your system. engine.
damage. Replace the components, if necessary.
g00843267
Illustration 88
g00843262
Illustration 86
2. Disconnect tube assembly (2), if equipped.

Disconnect tube assembly (3).
4. Remove hose (6) from the water pump.

35
i01650330
Crankshaft Front Seal -

Remove and Install
SMCS Code: 1160-010
Removal Procedure
Start By:
a. Remove the fan drive. Refer to Disassembly and

Assembly, “Fan Drive - Remove”.
b. Remove the guard assemblies. Refer to

Table 9
Required Tools
Part
A 1U-7430 Front Seal Installer 1
g00843262
Illustration 89
1. Install hose (1) on water pump (8) as you place

the water pump in position. Install bolts (7).
2. Place hoses (6) and (1) in position and tighten

the clamps.
3. Connect tube assembly (3). Connect tube

assembly (2), if equipped.
4. Install mounting block (4) with bolts (5).
5. Fill the coolant. Refer to Operation and

(DEAC) - Change” or refer to Operation and
Maintenance Manual, “Cooling System Extended
Life Coolant - Change” for your system.
End By:
a. Install the alternator. Refer to Disassembly and

g00852900
Illustration 90
1. Remove nuts (1) and bolts (2). Remove shrouds

(3) and (4).
36
g00852983 g00853048
2. Remove bolts (5), plate (6), damper (7), and 2. Position damper (7) and plate (6), and install
crankshaft front seal (8). bolts (5).
g00852992
Illustration 92
1. Clean crankshaft front seal (8) thoroughly and

use Tooling (A) to install the seal. Refer to
Specifications, SENR9500. Illustration 94
g00852900
3. Position shrouds (3) and (4). Install bolts (2) and

nuts (1).
37
End By:
a. Install the guard assemblies. Refer to Operation

and Maintenance Manual, “Guards - Remove
and Install”.
b. Install the fan drive. Refer to Disassembly and

Assembly, “Fan Drive - Install”.
i01629967
Air Compressor - Remove and

Install
SMCS Code: 1803-010
Removal Procedure
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Illustration 95 g00844475

suitable to collect and contain fluids on Caterpillar 4. Disconnect tube assemblies (1), (3), and (4).
products.
5. Remove bolt (8). Move the bracket and tube
Dispose of all fluids according to local regulations and assembly (4) out of the way.
mandates.
6. Loosen the clamp on hose (2) and remove the
1. Raise the hood. Operation and Maintenance hose from the air compressor.
Manual, “Hood (Engine Compartment) -
Raise/Lower”. 7. Disconnect hose assembly (6).
2. Remove the guard assembly on the left hand 8. Remove bolts (5). Remove air compressor (7).
side. Operation and Maintenance Manual, The weight of the air compressor is approximately
“Guards - Remove and Install”. 11 kg (25 lb).
3. Drain the coolant from the cooling system into a Installation Procedure
suitable container for storage or disposal. The
capacity of the cooling system is approximately Note: Check the O-ring seals for wear or for
37 L (9.8 US gal). Refer to Operation and damage. Replace the O-ring seals, if necessary.
(DEAC) - Change” or Operation and Maintenance
Manual, “Cooling System Extended Life Coolant
- Change” for your cooling system.
38
i01628603
Refrigerant Compressor -
Remove and Install
SMCS Code: 1802-010
Removal Procedure

erant.


dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.

pressure, release it slowly in a well ventilated area.
Personal injury or death can result from inhaling

g00844475
Illustration 96
1. Place air compressor (7) in position and install lit cigarette or other smoking method or inhaling
bolts (5). The weight of the air compressor is fumes released from a flame contacting air con-
approximately 11 kg (25 lb). ditioner refrigerant gas, can cause bodily harm or
death.
2. Connect hose assembly (6).
3. Connect tube assemblies (3) and (1) to the air wherever refrigerant gas may be present.
compressor.
4. Move tube assembly (4) and the bracket into erly remove the refrigerant from the air condition-
position and install bolt (8). ing system.
5. Connect tube assembly (4).
1. Raise the hood. Refer to Operation and
6. Install hose (2) and tighten the clamp. Maintenance Manual, “Hood (Engine
7. Fill the cooling system. The capacity of the
cooling system is approximately 37 L (9.8 US gal). 2. Remove the air conditioner belt. Refer to
Refer to Operation and Maintenance Manual, Operation and Maintenance Manual, “Belt (Air
“Cooling System Coolant (DEAC) - Change” or Conditioner and Fan) - Replace”.
System Extended Life Coolant - Change” for your 3. Recover the air conditioner refrigerant from the
cooling system. air conditioner system. The capacity is 2.2 kg
(4.85 lb). Refer to Service Manual, SENR5664,
8. Install the guard assembly on the left hand side. “Air Conditioning and Heating Systems with
Operation and Maintenance Manual, “Guards R-134a Refrigerant”. Refer to Special Publication,
- Remove and Install”. NEDG5065, “Air Conditioning Tools”.
9. Lower the hood. Operation and Maintenance

Manual, “Hood (Engine Compartment) -
Raise/Lower”.
39
4. Charge the air conditioner system. The correct

charge is 2.2 kg (4.85 lb). Refer to Service
Manual, SENR5664, “Air Conditioning and
Heating Systems with R-134a Refrigerant” for
5. Install the air conditioner belt. Refer to Operation

and Maintenance Manual, “Belt (Air Conditioner
and Fan) - Replace”.
6. Lower the hood. Refer to Operation and

i01632787
Refrigerant Accumulator (With

Desiccant) - Remove and
g00844206
Install
Illustration 97
SMCS Code: 7322-010-DSS
4. Disconnect hose assemblies (4) and (5).
5. Remove the cable strap and disconnect the Removal Procedure

wiring (1).
6. Remove bolts (2) and refrigerant compressor (3).

Installation Procedure erant.
Note: Check the O-ring seals for wear or for Contact with refrigerant can cause frost bite. Keep
damage. Replace the O-ring seals, if necessary. face and hands away to help prevent injury.


pressure, release it slowly in a well ventilated area.


lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
death.


g00844206
Illustration 98 erly remove the refrigerant from the air condition-
ing system.
1. Install refrigerant compressor (3) with bolts (2).
2. Connect hose assemblies (5) and (4). 1. Open the hood. Refer to Operation and
3. Connect wiring (1) and install the cable strap. Compartment) - Raise/Lower”.
40
2. Remove the right hand guard assembly. Refer to 2. Install bolt (3) in the weld nut from the inside
Operation and Maintenance Manual, “Guards side of the bracket.
3. Connect hose assemblies (4) and (2).
3. Recover the air conditioner refrigerant from
the air conditioner system. The correct charge 4. Charge the air conditioner system. The correct
is 2.2 kg (4.85 lb). Refer to Service Manual, charge is 2.2 kg (4.85 lb). Refer to Service
SENR5664, “Air Conditioning and Heating Manual, SENR5664, “Air Conditioning and
Systems with R-134a Refrigerant” for the Heating Systems with R-134a Refrigerant” for
procedure. Refer to Special Publication, the procedure. Refer to Special Publication,
NEDG5065, “Air Conditioning Tools” for the tools. NEDG5065, “Air Conditioning Tools” for the tools.
5. Install the right hand guard assembly. Refer to


g00845715
Illustration 99
4. Disconnect hose assemblies (2) and (4).
5. Remove bolt (3) on the back side of the bracket

from the weld nut.
6. Remove clamp (5) and refrigerant accumulator

damage. Replace the components, if necessary.
g00845715
Illustration 100
1. Place refrigerant accumulator (1) and clamp (5)

in position on the bracket.
41
i01632308
Refrigerant Condenser -
Remove and Install
SMCS Code: 1805-010
Removal Procedure

erant.


g00845520
Illustration 101
Slowly loosen the fitting. If the system is still under 3. Disconnect hose assemblies (3) and (5). Slide
pressure, release it slowly in a well ventilated area. hose assembly (3) out of the bottom of refrigerant
condenser (1).
refrigerant through a lit cigarette. 4. Remove bolts (4) from each side of the refrigerant
condenser.
lit cigarette or other smoking method or inhaling 5. Release latch assembly (2) from each side of the
fumes released from a flame contacting air con- refrigerant condenser. Remove the refrigerant
ditioner refrigerant gas, can cause bodily harm or condenser. The weight of the refrigerant
death. condenser is approximately 14 kg (30 lb).

wherever refrigerant gas may be present. Installation Procedure
Use a certified recovery and recycling cart to prop- Note: Check the O-ring seals for wear or for
erly remove the refrigerant from the air condition- damage. Replace the O-ring seals, if necessary.
ing system.
1. Open the hood. Refer to Operation and

2. Recover the air conditioner refrigerant from

the air conditioner system. The correct charge
is 2.2 kg (4.85 lb). Refer to Service Manual,
SENR5664, “Air Conditioning and Heating
Systems with R-134a Refrigerant” for the
procedure. Refer to Special Publication,
g00845537
Illustration 102
42
i01657536
Hood - Remove
SMCS Code: 7251-011
Removal Procedure
Table 10
Required Tools
Part Part
Tool Qty
Number Description
A 1U-8224 Lifting Sling 2
B 1U-8223 Lifting Sling 1
C 138-7575 Link Bracket 2
g00845520
Illustration 103
1. Place refrigerant condenser (1) in position and

install bolts (4) on each side of the refrigerant
condenser. The weight of the refrigerant
condenser is approximately 14 kg (30 lb).
Note: Move hose assembly (3) into position before

installing the refrigerant condenser.
2. Connect hose assemblies (3) and (5).
3. Fasten latch assembly (2) on each side of the

refrigerant condenser.
4. Charge the air conditioner system. The correct

charge is 2.2 kg (4.85 lb). Refer to Service
Manual, SENR5664, “Air Conditioning and
g00855514
Heating Systems with R-134a Refrigerant” for Illustration 104
NEDG5065, “Air Conditioning Tools” for the tools. 1. Remove bolts (1) on housing (2). Repeat for the
other side.
Maintenance Manual, “Hood (Engine 2. Remove housing (2).
43
g00855527
Illustration 105
3. Disconnect wiring harness (3).
g00855543
Illustration 107
4. Attach Tooling (A) onto bar (4). Use a suitable

lifting device and Tooling (A) in order to support
the front of the hood.
g00855539
Illustration 106
g00855553
Illustration 108
5. Remove shock (5) from the bracket and the

hood. Repeat for the other side.
6. Lower the hood.

44
i01657940
Hood - Install
SMCS Code: 7251-012
Table 11
Required Tools
Part Part
Tool Qty
Number Description
A 1U-8224 Lifting Sling 2
g00855568
Illustration 109 B 1U-8223 Lifting Sling 1
7. Remove the nuts, the washers, the bushing, and C 138-7575 Link Bracket 2
bolts (6).
8. Raise the back of the hood and use a 152 mm

(6 inch) block of wood to support the back of
the hood.
g00855614
Illustration 111
1. Place hood (7) into the original position on the

tractor.
g00855614
Illustration 110
9. Attach Tooling (C).
10. Attach Tooling (B) to Tooling (C) and to the lifting

device.
11. Remove the hood (7).

45
g00855568
Illustration 112
2. Raise the back of the hood and use a 152 mm

(6 inch) block of wood in order to support the
back of the hood.
3. Remove Tooling (B) and (C) from the lifting

device.
4. Install bolts (6), the bushings, the washers, and

the nuts.
5. Remove the block of wood.

g00855543
Illustration 114
6. Raise the front of the hood.
8. Lower the hood.
9. Remove Tooling (A).
g00855553
Illustration 113
7. Install shock (5) to the bracket with the clips.

Repeat for the other side. Illustration 115
g00855527
10. Connect wiring harness (3).

46
1. Remove bolts (1) from drive shaft (2).
g00855514
Illustration 116
g00850364
Illustration 118
11. Install housing (2).
2. Remove bolts (3) and safety strap (4).
12. Install bolts (1). Repeat for the other side.
3. Remove bolts (5) from the U-joint. Separate drive
i01644775
shaft (2) from the flex-drive coupling and remove
the drive shaft.
Drive Shaft - Remove and
Install Installation Procedure
SMCS Code: 3253-010
Removal Procedure
g00850364
Illustration 119
View of the drive shaft under the tractor
g00850177
Illustration 117
Bottom view under the tractor of the drive shaft
47
c. Remove the drive shaft. Refer to Disassembly

and Assembly, “Drive Shaft - Remove and Install”
for the machine that is being serviced.
d. Remove the refrigerant compressor. Refer

to Disassembly and Assembly, “Refrigerant
compressor - Remove and Install” for the
e. Remove the muffler. Refer to Disassembly and

Assembly, “Muffler - Remove and Install” for the
NOTICE
g00850177
Illustration 120 Refer to Special Publication, NENG2500, “Caterpillar
1. Position drive shaft (2) on the flex-drive coupling suitable to collect and contain fluids on Caterpillar
and install bolts (1). products.
2. Position the drive shaft on the U-joint and Dispose of all fluids according to local regulations and
install bolts (5). Tighten bolts (5) to a torque of mandates.
105 ± 20 N·m (77 ± 15 lb ft).
3. Install safety strap (4) with bolts (3). NOTICE

Keep all parts clean from contaminants.
i01711909 Contamination of the hydraulic system with foreign
material will reduce the service life of the hydraulic
Engine - Remove system components.
SMCS Code: 1000-011
To prevent contaminants from entering the hydraulic
system, always plug or cap the lines, fittings, or hoses
Removal as they are disconnected. Cover any disassembled
components and clean them properly before assem-
Table 12 bly.
Required Tools
Clean the hydraulic system properly after any major
TOOL Part Number Part Description Qty component exchange or especially after a component
A 1U-8223 Lifting Sling 2 failure, to remove any contamination.
B 1U-9200 Lever Puller Hoist 1
C 6V-3145 Load Leveling Beam 1
Start By:
a. Remove the cooling assembly. Refer to

Disassembly and Assembly, “Cooling Assembly -
Remove” for the machine that is being serviced.
b. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric starting
Motor - Remove” for the machine that is being
serviced.
48
Personal injury can result from hydraulic oil pres-

sure and hot oil.
Hydraulic oil pressure can remain in the hydraulic

system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not re-
leased before any service is done on the hydraulic
system.
Make sure all of the work tools have been lowered

to the ground, and the oil is cool before removing
any components or lines. Remove the oil filler cap
only when the engine is stopped, and the filler cap
is cool enough to touch with your bare hand.
g00854415
Illustration 122
2. Remove alternator wires (3), (4) and (5) from

alternator (2). Remove bolt (6) and the clip.
g00854394
Illustration 121
1. Remove bolt (1) and washers from the engine.
g00881005
Illustration 123
3. Remove two tube assemblies (10) and (11) from

the engine. Remove two clamps (7) and (9) on
exhaust pipe (8). Remove exhaust pipe (8) from
the engine.
4. Remove bolt (12) from light (13). Remove light

(13 ) from the engine. Repeat light removal for
opposite side of the engine.
49
8. Cut cable straps along harness (19). Disconnect

the wire at the inlet air heater relay (18).
9. Cut cable straps on harness (19). Remove bolt

(20) on the engine.
g00854440
Illustration 124
5. Remove nut (14) and the ground strap from the

engine.
g00855383
Illustration 125
6. Remove air cleaner indicator (15).
g00881012
Illustration 127
10. Remove one bolt in ECM connector (23).

Remove connector (23). Remove two hose
assemblies (21) and (22) from the engine.
11. Remove hose assembly (24) from fuel filter (25).
g00881006
Illustration 126
7. Cut cable strap (16). Remove hose (17).

g00854518
Illustration 128
50
12. Remove two dust ejector hose clamps (26) from 15. Remove bolts (31) from disconnect switch (32).
dust ejector tube (27). Remove dust ejector tube Move disconnect switch (32).
(27) from the engine.
g00881020
Illustration 131
16. Disconnect tube assembly (33). Remove nut (34)

and clamp from tube assembly (33). Remove
tube assembly (33) from the engine.
17. Disconnect tube assembly (36). Remove bolt

(37) from tube assembly (36). Remove tube
assembly (36) from the engine. Remove bolt (38)
from priming pump (39). Remove priming pump
18. Remove two bolts (35) from the rear engine

mount and two bolts (40) from the front engine
mount.
g00881014
Illustration 129
13. Remove bolt (28) and washers. Remove tube

14. Remove fuel line (30) from the engine.
g00854539
Illustration 130
51
NOTICE
Keep all parts clean from contaminants.
Contamination of the hydraulic system with foreign

material will reduce the service life of the hydraulic
system components.
To prevent contaminants from entering the hydraulic

system, always plug or cap the lines, fittings, or hoses
as they are disconnected. Cover any disassembled
components and clean them properly before assem-
bly.
Clean the hydraulic system properly after any major

component exchange or especially after a component
failure, to remove any contamination.
g00854629
Illustration 132
19. Attach a suitable lifting device to Tooling (C).

Attach Tooling (A) between the flywheel housing
and rear of the oil pan to Tooling (C). Attach
Tooling (B) to the front of the engine. Use Tooling
(B) to adjust the engine. Remove the engine
from the machine. The weight of the engine is
approximately 839 kg (1850 lb).
i01712100
Engine - Install
SMCS Code: 1000-012
Installation g00854629
Illustration 133
Table 13
Required Tools 1. Attach a suitable lifting device to Tooling (C).
Attach Tooling (A) between the flywheel housing
TOOL Part Number Part Description Qty and the rear of the oil pan to Tooling (C). Attach
A 1U-8223 Lifting Sling 2 Tooling (B) to the front of the engine. Use Tooling
(B) to adjust the engine. Install the engine
B 1U-9200 Lever Puller Hoist 1 to the machine. The weight of the engine is
C 6V-3145 Load Leveling Beam 1 approximately 839 kg (1850 lb).
52
g00881020
Illustration 134
2. Install two bolts (40) to the rear engine mount

and two bolts (35) to the front engine mount.
3. Install priming pump (39) to the engine. Install

bolt (38) to priming pump (39). Install tube
assembly (36) to the engine. Connect tube
assembly (36). Install bolt (37) to tube assembly
(36).
4. Install tube assembly (33) to the engine. Connect

tube assembly (33). Install nut (34) and clamp
to tube assembly (33).
g00881014
Illustration 136
6. Install fuel line (30) to the engine.
7. Install tube (29) to the engine. Install bolt (28)

and washers.
g00854539
Illustration 135
5. Position disconnect switch (32). Install bolts (31)

to disconnect switch (32).
g00854518
Illustration 137
8. Install dust ejector tube (27) to the engine. Install

two dust ejector hose clamps (26) to dust ejector
tube (27).
53
g00881006
Illustration 139
11. Install bolt (20) on the engine. Attach cable

straps on harness (19).
12. Connect the wire to the inlet air heater relay (18).
Attach cable straps along harness (19).
13. Install hose (17). Attach cable strap (16).
g00881012
Illustration 138
9. Install hose assembly (24) to fuel filter (25).
10. Install connector (23). Install one bolt in ECM

connector (23). Install two hose assemblies (21)
and (22) to the engine.
g00855383
Illustration 140
14. Install air cleaner indicator (15).

54
g00854440
Illustration 141
15. Install the ground strap to the engine. Install nut

(14).
g00854415
Illustration 143
18. Install alternator wires (3), (4) and (5) to

alternator (2). Install the clip and bolt (6).
g00881005
Illustration 142
16. Install light (13 ) to the engine. Install bolt (12)

to light (13). Repeat light installation for opposite
side of the engine.
17. Install exhaust pipe (8) to the engine. Install two g00854394
Illustration 144
clamps (7) and (9) to exhaust pipe (8). Install
two tube assemblies (10) and (11) to the engine.
19. Install bolt (1) and washers to the engine.
End By:
a. Install the muffler. Refer to Disassembly and

Assembly, “Muffler - Remove and Install” for the
b. Install the refrigerant compressor. Refer to

compressor - Remove and Install” for the
55
c. Install the drive shaft. Refer to Disassembly and

Assembly, “Drive Shaft - Remove and Install” for
the machine that is being serviced.
d. Install the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Install” for the machine that is being
serviced.
e. Install the cooling assembly. Refer to Disassembly

and Assembly, “Cooling Assembly - Install” for
the machine that is being serviced.
56
Index Section
Index
A Fan Drive - Remove............................................... 30
Removal Procedure ........................................... 30
Aftercooler - Remove and Install ........................... 20 Fuel Filter and Fuel Filter Base - Install (Primary and
Installation Procedure ........................................ 21 Secondary Fuel Filters) ....................................... 8
Removal Procedure ........................................... 20 Installation Procedure ........................................ 8
Air Cleaner - Remove and Install........................... 18 Fuel Filter and Fuel Filter Base - Remove (Primary
Installation Procedure ........................................ 19 and Secondary Fuel Filters) ................................ 6
Removal Procedure ........................................... 18 Removal Procedure ........................................... 6
Air Compressor - Remove and Install.................... 37
Installation Procedure ........................................ 37
Removal Procedure ........................................... 37 H
Alternator - Remove and Install ............................. 4
Installation Procedure ........................................ 4 Hood - Install ......................................................... 44
Removal Procedure ........................................... 4 Installation Procedure ........................................ 44
Hood - Remove ..................................................... 42
C Hydraulic Oil Cooler - Remove and Install............. 15
Cooling Assembly - Install ..................................... 12 Removal Procedure ........................................... 15
Cooling Assembly - Remove ................................. 10
Removal Procedure ........................................... 10 I
Crankshaft Front Seal - Remove and Install.......... 35
Installation Procedure ........................................ 36 Important Safety Information ................................. 2
M
D
Muffler - Remove and Install.................................. 21
Disassembly and Assembly Section...................... 4 Installation Procedure ........................................ 21
Drive Shaft - Remove and Install ........................... 46 Removal Procedure ........................................... 21
R
E Radiator - Install .................................................... 26

Electric Starting Motor - Remove and Install ......... 5 Radiator - Remove ................................................ 24
Installation Procedure ........................................ 5 Removal Procedure ........................................... 24
Removal Procedure ........................................... 5 Refrigerant Accumulator (With Desiccant) - Remove
Engine - Install....................................................... 51 and Install ............................................................ 39
Installation.......................................................... 51 Installation Procedure ........................................ 40
Engine - Remove ................................................... 47 Removal Procedure ........................................... 39
Removal............................................................. 47 Refrigerant Compressor - Remove and Install ...... 38
F Refrigerant Condenser - Remove and Install ........ 41
Fan - Remove and Install....................................... 29 Removal Procedure ........................................... 41
Fan Drive - Assemble ............................................ 32 T
Assembly Procedure.......................................... 32
Fan Drive - Disassemble ....................................... 31 Table of Contents................................................... 3
Disassembly Procedure ..................................... 31
Fan Drive - Install................................................... 33
57
Index Section
Water Pump - Remove and Install ......................... 33

Water Temperature Regulator - Remove and
Install ................................................................... 22
58
Index Section
59
Index Section

Charlenger 1870

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3

Accidental machine starting can cause injury or

To avoid accidental machine starting, turn the bat-

Place a do not operate tag at the battery discon-

Disassembly and Assembly

Alternator - Remove and Install

2. Turn the disconnect switch to the Off position.

3. Remove the belt. Refer to Operation and

5. Remove bolts (5), (6), (7), and (8).

6. Remove alternator (2) from the bracket.

4. Remove wiring (1), (3), and (4) from alternator

1. Place alternator (2) in position on the bracket.

2. Install bolts (7), (8), (6), and (5) in order to hold

3. Disconnect wires (1), (2), (5), and (6).

4. Remove bolts (3) and electric starting motor (4)

5. Install the guard assembly on the right side of

6. Turn the disconnect switch to the On position.

Electric Starting Motor -

1. Install electric starting motor (4) in the tractor

Fuel Filter and Fuel Filter Base

SMCS Code: 1261-011; 1262-011

Note: Mark the location and the orientation of all

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

Hot engine components can cause injury from

1. Disconnect hose assemblies (3) and (4) from

g00869131 2. Remove two port connectors (18) from filter base

5. Remove four bolts (9) which fasten filter base (8)

6. If necessary, remove five plugs (10) and remove

7. Remove stud (8A) from filter base (8).

i01686105 Primary Fuel Filter and Filter Base

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

1. Inspect all of the O-ring seals for wear or for

3. Install stud (8A) in fuel filter base (8). Tighten the

6. Connect hose (14) to water separator bowl (13).

4. Install filter base (15) and secure the filter base

5. Install O-ring seals (17) on port connectors (18).

6. Install filter element (19) on filter base (15).

7. Connect hose assemblies (6) and (7) to filter

7. Connect hose assemblies (3) and (4) to filter

8. Turn the fuel valve (5) to the ON position.

9. Close the hood.

10. Prime the fuel system and start the engine.

1. Inspect all of the O-ring seals for wear or for

2. Install O-ring seals (20) on plugs (21). Install

3. Install stud (15A) in filter base (15). Tighten the

Cooling Assembly - Remove

Start By: Do not smoke when servicing air conditioners or

Dispose of all fluids according to local regulations and

9. Remove bolts (3) from the bracket assembly.

4. Remove hose assemblies (1).

5. Plug hose assemblies with Tooling (A) and cap Illustration 16

12. Disconnect tubes (11) and (13).

13. Loosen the clamps on hoses (16) and (17).

7. Remove bolt (8) and the bracket.

8. Remove bolt (7) on the other side of the bracket.

Cooling Assembly - Install

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

Personal injury can result from contact with refrig-

Contact with refrigerant can cause frost bite. Keep

Protective goggles must always be worn when re-